Aquacal Great Big Bopper Specification sheet

LTM0239 rev 1
AquaCal AutoPilot
Great Big Bopper
Operation and Installation Manual

TABLE OF CONTENTS
SECTION 1 - GENERAL INFORMATION
1.1 Contacting AquaCal AutoPilot...............................................................................................1
1.2 Safety...................................................................................................................................1
SECTION 2 - OPERATION
2.1 Control Panel........................................................................................................................3
2.1.a Indicator Lights ...............................................................................................................3
2.1.b Control Buttons...............................................................................................................3
2.1.c LED Display....................................................................................................................3
2.1.d User Level Programs......................................................................................................4
Turning Heat Pump On................................................................................................. 4
Setting Operating Mode (“HEA”, “COO”, or “ACH”).......................................................4
Turning Heat Pump Off................................................................................................. 4
Setting Thermostats......................................................................................................4
Selecting Celsius or Fahrenheit....................................................................................4
Enabling Lockout Option...............................................................................................5
Unlocking Heat Pump...................................................................................................5
Disabling Lockout Option..............................................................................................5
2.2 Heating Water.......................................................................................................................6
2.3 Cooling Water.......................................................................................................................6
2.4 Heat Pump’s Defrost Operation ............................................................................................7
SECTION 3 - MAINTENANCE
3.1 Cleaning Equipment .............................................................................................................9
3.2 Monitoring Conditions.........................................................................................................10
3.2.a Pool Chemistry ............................................................................................................. 10
3.2.b Clearances....................................................................................................................10
3.2.c Water Flow....................................................................................................................10
3.2.d Irrigation and Storm Run-Off.........................................................................................10
3.4 Winterizing.......................................................................................................................... 11
3.5 Preventive Maintenance .....................................................................................................11
SECTION 4 - INSTALLATION
4.1 Equipment Specifications....................................................................................................13
4.1.a General.........................................................................................................................13
4.1.b Unit Dimensions............................................................................................................13
4.1.c Access Panels..............................................................................................................14
4.2 Placing Heat Pump.............................................................................................................14
4.2.a Indoor versus Outdoor Installation ................................................................................14
4.2.b Positioning Clearances.................................................................................................14
4.2.c Controlling Irrigation and Rainwater Runoff................................................................... 14
4.2.d Planning for Condensation............................................................................................ 15
4.2.e Mounting Pad Requirements.........................................................................................15
4.2.f Anchoring Heat Pump to Pad........................................................................................ 15
4.3 Plumbing ............................................................................................................................15
4.3.b Plumbing Diagrams....................................................................................................... 16

TABLE OF CONTENTS
4.3.c In-Line Chlorine Feeders...............................................................................................18
4.3.d Water Connections to Heat Pump.................................................................................18
4.3.f Maintaining Ability to Winterize .....................................................................................19
4.3.g Water Flow Rates and Operating Pressures................................................................. 19
4.3.h Water Flow (Pressure) Switch Adjustment....................................................................19
4.3.i Installations with In-floor Cleaning Systems..................................................................21
4.4Wiring................................................................................................................................. 21
4.4.a Standards.....................................................................................................................21
4.4.b General Requirements..................................................................................................21
4.4.c Grounding and Bonding................................................................................................21
4.4.d Sizing the Electrical Service.......................................................................................... 21
4.4.e Ground-Fault Protection................................................................................................22
4.4.f External Controls / Equipment.......................................................................................22
4.4.g Positioning Mode Jumper..............................................................................................23
4.5 Programming...................................................................................................................... 24
4.5.a Program Displays.......................................................................................................... 25
4.5.b Service Level Programs................................................................................................25
Entering Service Menu ...............................................................................................25
Deactivating Time Delay.............................................................................................25
Configuring for External Controller..............................................................................25
Configuring for Remote Flow Switch........................................................................... 26
Calibrating Water Sensor............................................................................................26
Calibrating Defrost Sensor..........................................................................................26
Adjusting Dead Band Differential................................................................................27
Re-Setting Heat Pump ("Back Door” Entry) ................................................................ 27
4.5.d Default Program Parameters ........................................................................................28
4.6 Optional Installation............................................................................................................28
4.6.a Pool and Spa Combination Heating ..............................................................................28
4.6.b Spa Heating Setback Option.........................................................................................28
SECTION 5 - TROUBLESHOOTING
5.1 Symptom / Resolution Charts ............................................................................................. 29
Control Panel Not Working .........................................................................................29
Heat Pump Not Running............................................................................................. 29
Heat Pump Running, Not Heating...............................................................................30
Heat Pump Tripping Breaker ......................................................................................31
Heat Pump Won’t Shut Off..........................................................................................31
Heat Pump Running, Not Cooling...............................................................................31
Water Coming From Heat Pump.................................................................................32
5.2 Fault Code Definitions ........................................................................................................33
“dPO” Indicator ........................................................................................................... 33
“PO” Indicator .............................................................................................................33
“dPC” Indicator ...........................................................................................................33
“PC” Indicator ............................................................................................................. 33
“HP” Indicator ............................................................................................................. 33
“HP5” Indicator ...........................................................................................................33
“LP” Indicator..............................................................................................................34

TABLE OF CONTENTS
“LP5” Indicator............................................................................................................ 34
“OtA” Indicator ............................................................................................................ 34
“FLO” Indicator ...........................................................................................................34
“FS” Indicator..............................................................................................................35
“CSE” Indicator...........................................................................................................35
“CEr” Indicator ............................................................................................................ 35
SECTION 6 - APPENDIX
6.1 Available Accessories.........................................................................................................37
6.2 Schematics......................................................................................................................... 37
6.3 Connecting External Controllers .........................................................................................37

Page 1
SECTION 1 - GENERAL INFORMATION
1.1 Contacting AquaCal AutoPilot
Web
www.AquaCal.com
Phone
[phone]
8-5 pm, Eastern M-F
Fax
[phone]
Please have your model and serial numbers available when contacting AquaCal AutoPilot for
questions, service, or parts.
1.2 Safety
For personal safety, and to avoid damage to equipment, follow all safety instructions displayed on the
equipment and within this manual. Repair and service of your heat pump must be performed by
qualified service personnel. Should you suspect your equipment is not performing properly, refer to the
section in this manual entitled: "Troubleshooting," to determine if a call for service is required.
Warranties will be voided if the equipment has been improperly installed, maintained or serviced.
Throughout this manual, safety signals have been placed where particular attention is required.
Safety Signals:
" WARNING" - signal relates to personal safety.
" CAUTION” - signal promotes avoiding damage to the equipment.
Follow all National Electric Codes (NEC) unless State or Local guidelines supersede. When installing
and using your heat pump, basic safety precautions must always be followed, including the following:
WARNING - Failure to heed the following may result in injury or death.
Repairs must be performed by a qualified technician. If service is deemed necessary, contact
installing dealer or AquaCal AutoPilot Customer Support for a service center in your area.
Heat pump contains refrigerant under pressure. Repairs to the refrigerant circuit must not be
attempted by untrained and/or unqualified individuals. Service must be performed only by
qualified HVAC technicians. Recover refrigerant before opening system.
Improper water chemistry can present a serious health hazard. To avoid possible hazards,
maintain pool / spa water per standards detailed later in this manual.
CAUTION - Failure to heed the following may result in equipment damage.
Maintain proper water chemistry in order to avoid damage to pump, filter, pool shell, etc.
Do not use glue on the threaded portion of the equipment’s unions. A glued-in-place union will
prevent the equipment from being properly winterized.
SAVE THESE INSTRUCTIONS

Page 3
SECTION 2 - OPERATION
2.1 Control Panel
The following information outlines how the control panel will operate for a standard installation. Control
Buttons will operate differently for custom installations; such as a heat pump connected to an external
controller. Please see appendix section entitled “Connecting External Controllers” for more information.
Figure 1
2.1.a Indicator Lights
“Pool”
Heat Pump is referencing the pool thermostat.
“Spa”
Heat Pump is referencing the spa thermostat.
“Cooling”
Indicates unit is cooling. Please note - both the compressor and the fan must be operating
before this light will illuminate.
“Desired
Temp”
Indicates temperature set point is displayed. This is displayed when “UP” or “DOWN” is
selected.
“Water Temp”
Indicates current water temperature is displayed.
“Heating”
Indicates unit is heating. Please note - both the compressor and the fan must be operating
before this light will illuminate.
Table 1
2.1.b Control Buttons
“Pool / Spa”
Select either the pool or the spa thermostat. (Inactive if unit under external control)
“Up”
Increase temperature set point.
“Down”
Decrease temperature set point.
“Mode”
Select heat pump operating mode.
Table 2
2.1.c LED Display
“XXX”
Heat Pump is on and displaying current water temperature.
“FLO”
No water flow is detected. Circulation pump is off or heat pump is not receiving correct water
flow.
“OFF”
Heat pump has been turned off via the mode selector button or the temperature set point has
been lowered below 45o F.
“FS”
Heat pump is in defrosting mode. See section entitled “Heat Pump’s Defrost Operation” on
page 7 for more information.
“888”
Control program is initializing. Displays only as power is applied to the heat pump. The
program version number will then be displayed.
Table 3

Page 4
2.1.d User Level Programs
The heat pump allows for two levels of programming; User-level and Service-level programming. This
section describes User-level programming.
STEPS
EXPLANATION
Turning Heat Pump On
Turn power on at external fuse
box or breaker disconnect.
Controller performs a lamp test. The display reads “888”.
Controller’s software version is briefly displayed.
Controller displays as described in section entitled “LED Display” on page 3.
Setting Operating Mode (“HEA”, “COO”, or “ACH”)
Press “MODE” control button
until “HEA” is selected.
Heat pump heats water to temperature set on thermostat.
Press “MODE” control button
until “COO” is selected.
Heat pump cools water to temperature set on thermostat.
Press “MODE” button until
“ACH” is selected.
Heat pump operates in either heating or cooling mode until reaching the
temperature set on the thermostat. Once reached, the heat pump maintains the
water temperature within four (4) degrees Fahrenheit of the temperature setting.
Turning Heat Pump Off
Press “MODE” control button
until “OFF” is selected.
Heat pump functions, values, and programming become unavailable. The
current water temperature is still displayed.
An alternate method of inactivating the heat pump is to lower the active
thermostat below 45º F. This turns the thermostat off, leaving the heat pump
itself available for programming.
Setting Thermostats
Set heat pump to an active
operating mode.
See “Setting Operating Mode (“HEA”, “COO”, or “ACH”)” in this chart for more
information.
Press "POOL/SPA" control
button to select thermostat.
The “Pool” or “Spa” indicator light specifies which thermostat is currently being
used.
Press “Up” or “Down” control
button to select desired
temperature.
The “Desired Temp” indicator light illuminates.
The thermostat’s temperature setting raises or lowers 1-degree per button
key press. The thermostat can be adjustable from a minimum of 45º F to a
maximum of 104ºF. Please note - Setting the temperature below 45ºF turns
the thermostat off.
Wait 15-seconds to allow heat
pump to exit programming
mode.
The “water temp” light turns on and the current water temperature is
displayed.
If the desired water temperature is different than the current water
temperature, the heat pump fan will activate. After a four minute time delay
the heat pump’s compressor will activate and the heating or cooling light will
illuminate depending on the operating mode selected.
Selecting Celsius or Fahrenheit
Press and hold “Up” and
“Down” buttons simultaneously.
"CF1" (Celsius / Fahrenheit) code appears.
Press “Up” or “Down” button to
select codes “0” or “1”.
Code “0” = Temperature displays in Celsius.
Code “1” = Temperature displays in Fahrenheit.
Wait 15-seconds to allow heat
pump to exit programming
mode.

Page 5
STEPS
EXPLANATION
Enabling Lockout Option
Press and hold “Up” and
“Down” buttons simultaneously
until “CF1” is displayed.
If “LOC” is briefly displayed, followed by a “0”, the heat pump is already locked.
A numerical password is required to proceed. See “Unlocking Heat
PumpUnlocking Heat Pump” on page 5 for more information.
Press “Pool/Spa” button until
“ELC” is displayed.
Any prior password can be viewed from this program.
Press “Up” button once to view
any existing numerical
password.
if desired, press “Up or “Down”
button to change or add a
numerical password
The password can be any number from “00” to “99”. Without knowledge of the
correct password, control adjustments will not be possible.
Press “Pool/Spa” Button to lock
in the password.
Press “Pool/Spa” button until
“ULC” is displayed.
Press “Up” button till “1” is
displayed.
Code “0” = User Lock disabled.
Code “1” = User Lock enabled.
Press “Pool/Spa” Button to save
selection.
Wait 15-seconds to allow heat
pump to exit programming
mode.
The heat pump lock-out feature is now enabled and the heat pump itself is
locked. Any future changes will now require a numerical password.
Unlocking Heat Pump
Press “Up” or “Down” Button.
If the heat pump is locked, “LOC” is briefly displayed followed by a “0”,
prompting the entry of the correct password.
Press “Up” button to enter the
password.
Press “Pool/Spa” Button.
If the correct password has been entered, the heat pump is unlocked. The
current water temperature is displayed and control settings are available.
The heat pump locks after being left idle for 15-seconds or after changing a
program option.
Before changing multiple program options it is recommended that the lockout
option be disabled. The lockout option can be re-enabled after all changes
are completed
Disabling Lockout Option
Press and hold “Up” and
“Down” buttons simultaneously
until “CF1” is displayed.
Press “Pool/Spa” button until
“ULC” is displayed
Press “Down” button until “0” is
displayed.
Code “0” = User Lock disabled.
Code “1” = User Lock enabled.
Wait 15-seconds to allow heat
pump to exit programming
mode.
All programmable features are now available.
Table 4

Page 6
2.2 Heating Water
1) Heat pump’s mode is set to “HEA”.
2) Thermostat is set to desired water temperature.
3) Water pump’s time clock is overridden to 24-hour operation. This is only necessary for an
initial startup. After the water reaches the desired temperature, the time clock can be reset
to a normal time frame operation.
4) Sufficient time is provided for heat pump to operate. The following calculations determine
how long it will take the heat pump to bring the water to temperature. The calculation is only
an approximation and varies per site condition. Additional heat pump runtime is needed to
compensate for cooling factors such as waterfalls, disappearing edges, fountains, etc.
HEATING TIME FORMULAS
1) POUNDS OF WATER
X
X
X
7.5
X
8.3
=
Length
of Pool
Width
of Pool
Average
Depth of
Pool
Gallons per
Cubic Feet
Pounds per
Gallon
Total Pounds of
Water to Heat
2) REQUIRED BTU'S
-
X
=
Desired
Temp
Current
Temp of
Water
Total Pounds of
Water to Heat
BTUs
Required
3) NUMBER OF HOURS
÷
=
BTUs
Required
BTU Output of
Heat pump
Total Hours
Required to Heat
Water
Figure 2
2.3 Cooling Water
1) Heat pump’s mode is set to “COO”.
2) Thermostat is set to desired water temperature.
3) Water pump’s time clock is overridden to 24-hour operation. After the water reaches the
desired temperature, the time clock can be reset to a normal time frame operation.
4) Sufficient time is provided for heat pump to operate.
COOLING TIME FORMULAS
1) POUNDS OF WATER
X
X
X
7.5
X
8.3
=
Length
of Pool
Width
of Pool
Average
Depth of
Pool
Gallons per
Cubic Feet
Pounds per
Gallon
Total Pounds
of Water
to Cool
2) REQUIRED BTU'S
-
X
=
Current
Temp of
Water
Desired
Temp
Total Pounds of
Water to Heat
BTUs
Required
3) NUMBER OF HOURS
÷
370,000
=
BTUs
Required
BTU Output of
Heat pump
Total Hours
Required to Cool
Water
Figure 3

Page 7
2.4 Heat Pump’s Defrost Operation
WARNING - Failure to heed the following may result in injury or death.
ROTATING FAN PROP HAZARD: fan may start during defrost cycle. Keep
hands clear of fan blade at all times.
Frost can form on the heat pump evaporator coil under certain weather conditions. When enough frost
has formed to inhibit heat pump operation, the heat pump starts a defrost cycle.
1) “FS” is displayed on the LED display
2) The heat pump cycles through 50-minutes of heating and 10-minutes of hot-gas defrost. A
moderate amount of frost can form on the air coil during the 50-minute heating period.
Steam can be seen coming off the evaporator during the 10-minutes of hot-gas defrost.
3) The fan operation is suspended during the 10-minute cycle permitting maximum heating of
the air-coil. However, if discharge pressure rises the fan will continue to operate.

Page 9
SECTION 3 - MAINTENANCE
WARNING - Failure to heed the following may result in injury or death.
Possible electric shock hazard - Disconnect power to all electrical devices on pad
when washing heat pump. Do not restore electrical power until equipment is
completely dry.
CAUTION - Failure to heed the following may result in equipment damage.
Do not use a pressure cleaner to wash heat pump. Damage to heat pump
components, such as the heat pump’s evaporator fins, will result. If using a hose-
end spray nozzle adjust spray pattern to low strength only.
3.1 Cleaning Equipment
Clean and polish heat pump frequently to prevent damage to equipment. More frequent service is
required for heat pumps located in sandy or coastal areas; where sand and salt spray can become
detrimental factors to equipment.
Washing
1) Remove upper access panel. (the panel that does not contain the control pad)
2) Being careful not to bend the evaporator’s fins, wash both sides of the evaporator coil and
outside cabinet using a low pressure water hose. Brush any debris inside the cabinet
towards the open access panel and remove from heat pump.
3) While the heat pump is still wet, use an approved cleaning agent and pump spray bottle to
coat the exterior of the heat pump.
4) Avoiding the evaporator fins, use a detergent-dampened cloth to wipe the heat pump's
exterior cabinet.
5) Flush all exterior surfaces and both sides of evaporator coil with fresh water using a low
pressure water hose.
6) Again avoiding the evaporator fins, dry exterior cabinet using a soft cloth. Allow evaporator
coil to air dry.
7) Confirm equipment pad is dry, and being sure not to over tighten screws, re-install access
panel.
Polishing
1) Do not touch, or otherwise attempt to polish the evaporator. Polish the heat pump’s cabinet
panels using an approved polishing agent and following the manufacturer’s instructions.
2) Rinse the heat pump panels with fresh water and wipe and buff panels using a dry soft cloth.
3) Allow heat pump interior and surrounding equipment to “air-dry” for several hours prior to
restoring electrical power.
APPROVED CLEANING AGENTS
Fantastic
409
All Power Plain Detergent (3% solution)
Cascade (preferred if also cleaning the evaporator)
APPROVED POLISHING AGENTS
Simoniz Wax
Aero Wax
Glo-Coat
Armorall Protectant (for use on cabinet surfaces only; do NOT apply to evaporator).
Table 5

Page 10
3.2 Monitoring Conditions
3.2.a Pool Chemistry
CAUTION - Failure to heed the following may result in equipment damage.
Stop water flow when refinishing or acid washing pool. Failure to follow these
instructions may damage equipment and voids heat pump warranty.
CAUTION - Failure to heed the following may result in equipment damage.
To avoid damage to equipment, monitor and maintain chemistry within
recommended levels.
Check water chemistry regularly and maintain within recommended levels as shown in Table 6.
Standards for commercial applications vary in different areas. Follow all local applicable codes.
CHEMICAL
POOLS
SPAS
Chlorine
1.0 –3.0 ppm
1.5 –3.0 ppm
Bromine
2.0 –4.0 ppm
3.0 –5.0 ppm
pH
7.4 –7.6 ppm
7.2 –7.8 ppm
Total Alkalinity
80 –140 ppm
80 –120 ppm
Calcium Hardness
200 –400 ppm
200 –400 ppm
Total Dissolved Solids
1,000 –2,000 ppm
1,500 ppm above start-up TDS in
spas
Table 6
3.2.b Clearances
Maintain airflow clearances around heat pump for maximum product efficiency. See section entitled
“Positioning Clearances” on page 14 for more information.
3.2.c Water Flow
Water flow through the heat pump may be reduced to a point where internal safety devices will shut off
the heat pump (i.e.: “HP” or “HP5”). Maintain equipment as outlined below to prevent water flow issues:
Operate water filtration devices per manufacturer's specifications. Dirty filters can cause reduced
water flow to the heat pump. The higher the pressure on the filter gauge, the lower the flow rate.
Keep baskets free of debris. Similar to a dirty filter, large amounts of debris in the pump and
skimmer baskets can reduce water flow..
Check for improper valve settings. A partially closed valve after the filter, or a full-open bypass
around the heat pump, will cause insufficient water flow through heat pump.
3.2.d Irrigation and Storm Run-Off
Irrigation water spray can damage heat pump components. Regardless of water quality, it is important
that irrigation be directed away from the heat pump. Prevent rainwater runoff from pouring directly into
the heat pump. The heat pump is designed to withstand normal rainfall, but solid streams of water from
roof drip-lines may eventually damage heat pump components. If the heat pump resides beneath a roof
edge a rain leader (gutter) or rain shield is required.

Page 11
3.4 Winterizing
CAUTION - Failure to heed the following may result in equipment damage.
Failure to properly winterize heat pump may result in serious equipment damage. Freeze
damage is not covered under the heat pump warranty.
While the plumbing connections are in the winterized condition (not fully tightened), it is
imperative pool/spa water not be circulated through the heat pump. Loss of water through loose
plumbing connections may result in damage to circulating pump, pool/spa structure, and/or other
equipment.
There are two freeze conditions requiring heat pump attention. A light-freeze is when ambient air
temperature falls below 32 degrees Fahrenheit for less than 8 hours. A hard-freeze is when ambient air
temperature falls below 32 degrees Fahrenheit for 8 or more hours.
Light-Freeze Conditions
Typically during light-freeze conditions circulating (moving) water will not freeze. Override time clocks
and allow filtration system to run continuously during light-freeze conditions. In areas where freezing
conditions are prevalent and sustained, the heat pump MUST be winterized for hard freeze conditions.
Hard-Freeze Conditions
1) Disconnect all electrical power to heat pump; turn “OFF”water circulation pump.
2) Disconnect the plumbing to the heat pump at connection unions, (removal is counter-
clockwise).
3) Wait until water has completely drained from equipment. Expect to see a lot of water drain
out at first, and then a small amount to continue to drain out over a long period.
4) After heat pump is fully drained, partially reconnect plumbing connection unions. (This
prevents insects and vermin from entering the plumbing during the winterized period and still
allows condensation to drain from the heat pump.)
5) When ready to use heat pump again, hand-tighten connection unions.
3.5 Preventive Maintenance
WARNING - Failure to heed the following may result in injury or death.
Annual inspection and service must be performed by a qualified pool and heat
pump specialist in order to prevent physical injury or damage to equipment.
An annual inspection and maintenance program is strongly recommended starting one (1) year after
installation of heat pump. See Figure 4 for recommended inspection checklist. AquaCal AutoPilot can
perform this service in limited areas. Contact Customer Support for more information.
Preventive Maintenance 20-Point Checklist

Check Water Flow

Oil Fan Motor (As Applicable)

Clean Evaporator Coil

Check Fan Motor Amperage Draw

Check Relay Contacts

Check Pool & Spa Water Chemistry

Check Capacitor Values

Check and Clean Condensate Drains

Check Refrigerant Levels

Check Compressor Amperage Draw

Clean Heat Pump Cabinet

Check Water Pump Amperage Draw

Check Fan Blade Clearances

Acid Wash Source Coil (As Applicable)

Check Flow/Pressure Switch

Check Air Temperature Change Through Evaporator

Check Electrical Connections

Check Operating Controls and Temperature Sensors

Check Proper Voltage To Unit

Check Water Temperature Change Through Condenser
Figure 4